Forced-Air Cooling

For many years produce has been cooled by simply storing it in a refrigerated room, a process
known as room cooling. This method is generally sufficient for keeping produce at a low
temperature once it has been cooled, but it often does not remove field heat rapidly enough to
maintain the quality of highly perishable crops. Room cooling is very often inadequate for
produce stored in large containers, such as bulk boxes or pallet loads, and for produce that
requires immediate cooling.

In the room cooling process, heat is removed slowly from only that produce near the outside of
the container. Near the center of a container, heat is often generated by natural respiration more
rapidly than it can be removed, causing the temperature to rise. Some types of produce, such as
strawberries, must be cooled as quickly as possible after harvesting to preserve its fresh quality.
Even a delay of several hours may be enough to reduce quality considerably. In such cases, room
cooling is not fast enough to prevent serious damage.

To preserve quality, fresh produce should be cooled to its lowest safe (optimum) storage
temperature as quickly as is practical and economical. Forced-air cooling is much faster than room
cooling and is being used increasingly in North Carolina to cool produce quickly. It offers these
advantages:

It decreases the time the produce remains at elevated temperatures, thereby
reducing deterioration;

It results in shorter cooling times and thus more efficient use of the
cooling facility;

It can cool produce effectively in a variety of unopened containers
without wetting it or subjecting it to excessive handling;

It is often more energy efficient than room cooling when large volumes
of produce must be cooled;

An available room-cooling facility with adequate cooling capacity can be
converted to forced-air cooling with only a relatively small
investment in fans

Energy-Efficient Cooling Practices

The energy cost for forced-air cooling can be greater or less than that for simple room cooling,
depending on how carefully the system is used. The faster cooling possible with the forced-air
method allows for greater use of the cooling facilities, reducing overall operating costs. In
addition, since the amount of time required to cool a load of produce is much shorter, less energy
is needed to remove heat produced by respiration and to overcome heat gain through the walls,
ceiling, and floor of the building.

On the other hand, forced-air cooling is likely to increase the overall energy cost slightly by
increasing electrical demand, a measure of the rate at which electricity is consumed. Demand cost
contributes significantly to the electrical power bill for most cooling facilities. To reduce demand
cost, produce should not be cooled any faster than necessary. Forced-air cooling can also
increase cooling cost by increasing the cooling load per unit of time. Quicker cooling requires
larger refrigeration units, the cost of which must be amortized over the life of the facility. The
benefits of forced-air cooling, however, far outweigh the costs.

Forced-air cooling is a useful tool for preserving the quality of fresh produce. It is most effective
when the produce demands quick cooling or when the amount of produce to be cooled per day or
week is large enough to justify the increased equipment and electrical demand costs.

Cooling Rate

Forced-air cooling is accomplished by exposing packages of produce in a cooling room to higher
air pressure on one side than on the other. This pressure difference forces the cool air through the
packages and past the produce, where it picks up heat, greatly increasing the rate of heat transfer.
Depending on the temperature, airflow rate, and type of produce being cooled, forced-air cooling
can be from 4 to 10 times faster than room cooling.

The graph of time and temperature in Figure 1 illustrates the response of a typical commodity to
airflow rates. The beginning temperature of the produce (pulp temperature) is represented by Ta.
This temperature varies with ambient conditions and the amount of field heat in the produce; it
normally ranges from 60 to 90 F.

Figure 1. Cooling time for various airflow rates.

The desirable air temperature inside the cooling room, Tb, depends primarily on the type of
commodity. Few types of produce will tolerate temperatures below freezing, although some, such
as strawberries and apples, require near-freezing storage temperatures. Many others, such as
squash and cucumbers, will sustain chill injury if exposed to temperatures lower than 45 F.

The interior air temperature, Tb, is best measured by a thermometer positioned away from the
exterior walls, ceiling, and produce containers. In practice, this temperature is regulated by the
thermostat setting of the refrigeration system. Correct storage temperatures for most types of
produce grown in North Carolina are given in Extension Publication AG-414-1, Maintaining the
Quality of North Carolina Fresh Produce: Introduction to Proper Postharvest Cooling and
Handling Methods.

Curve A in Figure 1 represents the comparatively slow rate of cooling that can be expected
without forced air movement (room cooling). Curves B and C demonstrate the increase in
cooling rate possible with airflow rates of 1/2 and 1 cubic foot per minute per pound of produce,
respectively.

The rate of cooling, represented by the slope of the curve, decreases as the produce temperature
approaches the temperature of the room air. Reducing the temperature the last few degrees may
take from several days to several weeks and is of little practical importance. In comparing cooling
times for various methods, the time required to lower the pulp temperature to 7/8 of the difference
between Ta and Tb is the value often used. On the graph, the
7/8 cooling time in still air is more than 7, compared to just over
1 for produce cooled with an airflow of 1 cubic foot per minute per pound of produce.

Since the cooling rate for a forced-air system is much greater than for room cooling, a refrigeration system of
larger capacity may be required. Whether an existing system sized for room cooling will be sufficient for
conversion to forced-air applications depends on a number of factors.
These include the size of the original system, the anticipated future cooling
loads, and the use factor of the facility. A qualified refrigeration contractor or a refrigeration specialist
with the Agricultural Extension Service can help in determining whether additional refrigeration capacity will be
needed.

Air Management

Fans supplied with the refrigeration equipment are used to cool the air by forcing it past the
evaporator coils. These fans are not large enough, nor are they properly located in most cases, to
force air directly past the produce. Furthermore, the chilled air leaving the evaporator coils is
generally much too cold for most types of produce. It must be mixed with the warmer air inside
the room to prevent chill injury. Therefore, additional fans are required to move the air past the
produce. To achieve good air distribution, these fans should pull, never blow, the cooled air
through the produce as fast as practical.

Several different fan positions and produce stack-ing arrangements have proven successful for
forced-air cooling. The shell arrangement shown in Figure 2 uses a portable pallet-mounted fan
and is preferred by many because of its versatility. Two parallel rows of produce, positioned
approximately 2 to 3 feet apart and covered by a cloth or plastic strip, form the shell. Cold air
pulled through the produce flows through the space between the rows and out through the fan. In
another arrangement known as the "cooling wall" (Figure 3), the fans are located permanently
along one wall. This design might be more convenient for producers and shippers who handle
large volumes of produce, especially if they always handle the same commodity or compatible
ones. Both types of systems are widely used in North Carolina.

Figure 2. Shell arrangement with portable pallet-mounted fan.

Figure 3. Cooling wall arrangement with permannently mounted fans.

Because air is forced through the produce packages by the difference in air pressure between the
opposite sides, it is necessary to fill the containers properly and stack them in such a way as to
minimize voids and openings. Openings between containers allow the air to circumvent the
produce, reducing cooling efficiency. Baffles may be positioned over unavoidable openings to
direct the air through the produce. Double stacking should be avoided since even powerful
forced-air fans have difficulty pulling air through more than one pallet width (3 to 4 feet) of produce.

In addition to controlling the temperature and airflow, it may be necessary to control the
humidity. Moving air tends to remove water from the surface of produce, causing wilting,
shrinkage, and general loss of quality and value. Most produce items require a relative humidity
in the range from 90 to 98 percent if they are to be kept for more than a few hours in cold storage
before shipment.

If the condensation from the evaporator coils is drained to the outside, the humidity in refrigerated
rooms may become quite low. The amount of condensation that collects on these coils may be
decreased substantially by limiting the temperature drop through them to 5 F. This can be
accomplished by increasing the size or number of the coils. In practice, relative humidity levels
above 80 or 85 percent cannot easily be achieved without some type of humidification system or
very careful management.

Low humidity may be corrected by various types of commercial humidification systems. Many
operators simply hose down the floors from time to time, but this approach may not be consistent
with good sanitation nor particularly effective in many situations. On the other hand, excessively
high humidity for long periods can also be detrimental because it encourages the growth of molds
and fungi. Although a high-quality humidistat can be used to control the humidifier, the most
consistently accurate method to measure relative humidity is with a wet-bulb thermometer.
Construction details and directions for the proper operation of a wet-bulb thermometer may be
obtained from your county Agricultural Extension Service agent.

Fans

Not all fans are designed to move air at the volume and static pressure required for forced-air
cooling. (Static pressure in this case is the resistance to air movement presented by the packages
of produce.) Although either centrifugal ("squirrel cage") or propeller fans may be used, their
specifications should be carefully evaluated to ensure that they will deliver an adequate quantity of
cooling air at higher pressures. Fan curves giving pressure and volume data, such as the one
shown in Figure 4, are available for most commercial or industrial fans. Notice that there is an
inverse relationship between pressure and airflow rate. In the figure, for example, the flow rate at
1 inch of water pressure is 4,000 cubic feet per minute (cfm), whereas at a pressure of 1/2 inch
the flow rate increases to over 6,000 cfm.

Figure 4. Typical fan curve.

In addition to airflow rate and temperatures, several other variables influence the time required to
cool produce with forced air, including the size and shape of the produce and the configuration
and venting of the containers. In practice, however, an airflow rate of approximately 1 to 3 cubic
feet per minute at 1/2 inch static pressure should be sufficient for most applications. Accurate
cooling data for a specific set of conditions can be acquired only by conducting field tests.

The airflow rate through a fan system in a cooling setup may be measured with sufficient accuracy
using an inexpensive U-tube manometer mounted to the fan (Figures 5 and 6). U-tube
manometers are designed to measure differences in air pressure. One side of the manometer is
connected on the upstream side of the fan as far as possible from the blades and the other end is
open to the room air. By knowing the static air pressure through the fan and consulting the
performance chart usually supplied with new fans, the airflow rate may be accurately determined.

Figure 5. U-tube manometer.

Figure 6. Pallet-mounted forced-air cooling fan.

In addition, it is also useful to mount a thermometer on the downstream (exhaust) side of the fan.
By comparing the temperature of the air as it exits the fan with the temperature of the room air, it
is possible to determine the cooling rate. The following example will illustrate the procedure.

A manometer attached to a fan pulling air through 8,000 pounds of peppers shows a static
pressure difference of 1/2 inch of water. The performance chart for this fan shows an airflow rate
of 14,000 cubic feet per minute at this static pressure. The room air temperature is measured at
45 F and the temperature of the air exiting the fan is 52 F. Since raising the temperature of 54
cubic feet of air 1 F requires one Btu of heat energy:

(14,000)(52-45)
Heat Loss = --------------- = 1,815 Btu/minute
54

It takes approximately 1 Btu to lower the temperature of 1 pound of peppers 1 F. Therefore, at a
heat loss rate of 1,815 Btu per minute, the temperature of the 8,000 pounds of peppers is being
reduced approximately 1 F every 4.4 minutes.

8,000
----- = 4.4
1,815

The rate of heat loss changes continuously during the cooling period. As shown in Figure 1, it is
greatest at the beginning of the cooling cycle (when the difference between product temperature
and air temperature is greatest) and ultimately tapers off to zero.

The interior of a cooling room is often damp or even wet. Fan motors should therefore be of the
totally enclosed, fan-cooled type (TEFC) and fully grounded according to local electrical codes to
prevent shock.

It is also a good idea to control the fan with a line-voltage thermostat mounted in the airstream.
The thermostat will stop the fan when the produce has cooled to a predetermined point, thus
saving energy. It will also reduce the drying effects of the cooling air because it will not allow the
fan keep running for an extended period after the produce has cooled. The thermostat should be
set at 5 to 8 F above the temperature of the room air.

Plans and directions for building a portable pallet-mounted fan similar to the one shown in Figure
6 are found at the end of this publication. This fan is capable of moving more than 11,000 cubic
feet of air per minute against a static pressure of 3/8 inch of water. It is suitable for use in a
variety of forced-air cooling applications.

Containers

A variety of produce packages have been used with forced-air cooling. They include fiberboard
boxes, wooden wirebound crates and hampers, and bulk boxes. The only requirement is that
sufficient open space be provided in the sides and bottom to ensure adequate air movement
through the containers. Most commercial containers are designed with adequate open space. If
not, openings should be added or enlarged so that 5 to 8 percent of the lateral surface and 3 to 5
percent of the bottom is open. Slots at least 1/2 inch wide are better than circular openings that
may be blocked by produce. These openings should be well distributed over the surface of the
container to ensure good air distribution.

Forced-Air Cooling Fan

Sponsored by the Energy Division, North Carolina Department of Commerce, with petroleum
violation escrow funds, in cooperation with the Agricultural Extension Service,
North Carolina State University. However, any opinions, findings, conclusions, or
recommendations expressed herein are those of the authors and do not reflect the
views of the Energy Division, North Carolina Department
of Commerce.

Published by

THE NORTH CAROLINA AGRICULTURAL EXTENSION SERVICE

North Carolina State University at Raleigh, North Carolina Agricultural and Technical State
University at Greensboro, and the U.S. Department of Agriculture, cooperating. State University
Station, Raleigh, N.C., Chester D. Black, Director. Distributed in furtherance of the Acts of
Congress of May 8 and June 30, 1914. The North Carolina Agricultural Extension Service offers
its programs to all eligible persons regardless of race, color, or national origin and is an equal
opportunity employer.